ME3 Manual Mobile Cabinetpdfs.findtheneedle.co.uk/19325..pdf · ME3 Manual (Mobile Cabinet).doc 26...

ME3 Mobile Cabinet Three PhaseFrequency Converter,

Operation and Maintenence.

ME3 Mobile Cabinet Manual Rev 1

web - www.magnuspower.co.uk

e-mail - [email protected]

ME3 Mobile Cabinet Three Phase Frequency Converter - Manual

Magnus Power

Magnus Power29 - 30 Brunel Road, St Leonards on Sea, East Sussex, TN38 9RT. United Kingdom

Telephone +44 (0) 1424 853 013 (Sales & Service)+44 (0) 1424 853 464 (all other Enquires)

Fax +44 (0) 1424 853 2 268

[email protected]

[email protected]

29 - 30 Brunel Road, Churchfields Industrial Estate, St. Leonards-on-SeaEast Sussex. TN38 9RT. United KingdomSales & Service : 01424 853 013 All Other Departments : 01424 853 464 Fax : 01424 852 [email protected] [email protected]

ME3 Manual (Mobile Cabinet).doc 26 July 2006

2

CONTENTS

SPECIFICATION 3

OPERATING RESTRICTIONS AND SAFETY ADVICE 3

INSTALLATION AND COMMISSIONING 4

Installation Procedure 5

GENERAL ARRANGEMENT 6

CONTROL PANEL 7

Pushbutton Controls 7

Mimic Diagram Indicators 7

SWITCHGEAR COMPARTMENT 8

Auxiliary Power Supply Switch 8

FIRST START UP 9

NORMAL OPERATION 9

Standby Condition 9

Starting Up 10

Shutting Down 10

Restarting after a Supply Interruption 10

ALARM CONDITIONS 11

Overload 11

Over Temperature 11

Short Circuit 12

Inverter Fault 12

UNREPORTED PROBLEMS 13

ELECTRICAL MEASUREMENTS 13

MAINTENANCE 13

Preventive Maintenance 13

Corrective Maintenance 14

Warranty Repair 14


3

SPECIFICATION

Three Phase + Neutral 380/400/415V 50Hz

Voltage Tolerance +/-10%

Input Requirement

Frequency Tolerance +/-5%

Three Phase + Neutral 115V Phase-Neutral

Frequency 200V Phase-Phase

400Hz +/-1%

The maximum load permitted on any phase is one third of the total output rating

There is no requirement for the load to be balanced on all phases

Output Capability

The output neutral is linked to mains earth (ground) internally. This link may be removed if floating output is required, or if the output neutral is to be grounded elsewhere.

0 to 40 degrees, derating to 30 degrees at 2000m

40 to 60% RH (recommended)

0 to 90% RH (extreme)

Operating Environment

Below 55dBA at 1m

OPERATING RESTRICTIONS AND SAFETY ADVICE

Ensure adequate air circulation around the unit in normal operation, for correct

function of the cooling fans. Allow for the dissipation of waste heat produced

by the Converter, which will amount to around 10% of its output rating when

operating at full load. Do not attempt parallel operation of the Converter output

with any other power source.

Dangerous voltages are present at numerous points within the Converter,

and great care should be taken if running with any of the covers removed.


4

The DC Busbars are alive at 750V dc during Converter operation. A

fault current of hundreds of amps is available within the DC Circuitry,

and great care should be taken if using tools in this area when there is

any possibility of charge remaining. Discharge Resistors are connected

across the DC Busbars, and these will take about 2 minutes to complete

their task after power is removed.

INSTALLATION AND COMMISSIONING

Installation includes positioning the Converter, the provision of input and output

cables and an input isolator, and connection of the input and output cables to the

Converter terminals. Installation is normally carried out by the customer, or by

an electrical contractor working on behalf of the customer.

Magnus Power recommends that the system is commissioned by one of their

engineers after installation, but the customer may opt to carry out this work. It

consists of checks on the operating environment, the voltage and phase rotation

of the incoming supply, input and output connections at the Converter, and the

earth (ground) connection. Internal plug-and-socket connections are checked

for correct mating. After initial start-up of the system, its operation will be

checked and any necessary adjustments made. Finally a demonstration of the

operation of the system will be offered, and a commissioning status report will

be prepared.

If Magnus Power does not carry out commissioning, it is recommended that

when power is applied for the first time, the Output Circuit Breaker is left set to

Off. The procedure is described elsewhere in this document.


5

Installation Procedure

Position the Converter at the required location, and ensure that its weight is

adequately supported. Allow at least 400mm clearance at the rear for air

circulation, and for access to the circuit breakers (inside narrow door at rear). A

similar clearance will be needed at the front, for ventilation and to allow an

operator to reach the control panel.

Access to the sides of the machine is not required during normal operation, but

may be needed for maintenance purposes. If flexible input and output cables of

suitable length are fitted during installation, it will be possible to move the

machine on its casters between a normal service position where it takes up least

space, and a maintenance position offering all round access.

The input and output terminals are at the lower rear of the cabinet behind a

removable terminal cover, which may be drilled for cable access. Connect the

output (load) and input (supply) cables as indicated by the terminal labels,

ensuring a sound supply earth (ground) connection to the earth terminal.

It is common practice for the neutral of any ac supply system to be grounded

(earthed) at its source, and for the converter input this link is usually made by the

supply authority at their substation. In accordance with this principle, the output

neutral of the Converter is grounded internally. If you require floating output, or

if your distribution system has an existing neutral earthing link, you will need to

remove the internal link. Instructions for removal of the link will be provided on

request.

When installation is complete, refit the terminal cover, to prevent casual access

to the electrical connections.


6

GENERAL ARRANGEMENT


7

CONTROL PANEL

Indications are given by a mimic diagram, and a four-line alphanumeric display.

The pushbuttons on the mimic diagram control the operation of the Converter,

and the buttons below the display allow scrolling of its contents.

The first two lines of the display provide measurements of input and output

values, and the third and fourth lines give status messages.

During normal operation of the Converter, the mimic diagram will show no

indications, and the status display will read “Power System – OK” and

“P.S. Use – nnn Days”.

Pushbutton Controls

Start Output (green)

Stop Output (red, press both)

Reset Alarm Indication (“R”)

Scroll Status Display (up and down)

Scroll Meter Readings (up and down)

Mimic Diagram Indicators

Supply Voltage Low (red, in left hand box on mimic diagram)

Output Off (red, in right hand box on mimic diagram)

1 2

1 2 3 2

4

5

6

7


8

SWITCHGEAR COMPARTMENT

Access to this area is via the narrow door at the rear of the Converter, to the

right of the terminal cover. It contains the Auxiliary Power Supply Switch, the

Input Circuit Breaker and the Output Isolator.

Setting either the Input Circuit Breaker or the Output Isolator to the Off position

will prevent output, but various parts of the Converter will remain alive, including

the input terminals. To ensure that all connections are dead, isolate the

Converter elsewhere and wait at least two minutes to allow stored voltages to

decay before touching any internal component.

Auxiliary Power Supply Switch

The Converter includes a small rechargeable battery, which ensures a continued

supply of power to the control electronics during supply transients, or extreme

step changes of load. The Auxiliary Power Supply Switch controls the flow of

power from the battery to the control electronics, and should be switched off

during a planned disconnection of the Converter from the Supply of more than 1

hour, to avoid unnecessary discharge of the battery.

If the battery becomes discharged as a result of an unexpected break in the

supply, such as a power cut outside working hours, it will be recharged

automatically when the supply is restored.

If the Auxiliary Power Switch is left set to Off then the Converter will appear to

operate normally, but it may shut down unnecessarily during supply transients or

under extreme load conditions.


9

FIRST START UP

Before starting the Converter for the first time after installation, set the Output

Isolator to Off. Set the Auxiliary Power Switch to On, and check that the mimic

diagram indicates Supply Voltage Low and Output Off. After connecting power

with the Input Circuit Breaker On, check that the Supply Voltage Low indicator

(red light in the left hand box on the Control Panel) goes off within 10 seconds.

If this does not happen, set the Input Circuit Breaker to Off, and seek technical

advice.

If the Control Panel illuminates as described, allow the starting sequence to

complete to the Standby Condition as described in the following paragraph, and

then continue through Starting Up and Shutting Down. The Output Isolator may

now be closed, and the Converter may be used as described under Normal

Operation.

NORMAL OPERATION

Standby Condition

On application of input power, either externally or by setting the Auxiliary Power

Switch and the Input Circuit Breaker to On, the Converter will initialise. During

this process, which may take up to 30 seconds to complete, there may be an

indication of Supply Voltage Low before the display changes to Output Off.

This is the Standby condition, in which the Converter is ready to run but is not

producing any output. The status message display will read “Inverter Off” and

the audible alarm will sound. Press the Reset button to silence the alarm and to

clear the status message.


10

Starting Up

Press the green Start Output button to commence operation. The mimic diagram

indication will change from Output Off to no indications, and if the Output

Circuit Breaker is On, power will be supplied to the load.

The status messages will read “Power System - OK” and “P.S Use – nnn

Days”.

Shutting Down

Press both of the red Stop Output buttons. The Converter will revert to the

Standby condition, and the mimic diagram indication will change from no

indications to Output Off. The status message display will read “Inverter Off”

and the audible alarm will sound. Press the Reset button to silence the alarm and

clear the status message.

Disconnect the load (if required) by setting the Output Isolator to Off.

Remove Converter input power (if required) by setting the Input Circuit Breaker

to Off, or by setting the Auxiliary Power supply switch to Off and isolating

elsewhere.

Restarting after a Supply Interruption

If a power cut occurs during normal operation, then when power is restored the

Converter will initialise to the Standby condition. The status message display

will read “Inverter Off” and the audible alarm will sound. Press the Reset button

to silence the alarm and to clear the status message.

Press the green Start Output button to commence operation. The mimic diagram

indication will change from Output Off to no indications and if the Output


11

Isolator is On, power will be supplied to the load.

The status messages will read “Power System - OK” and “P.S. use – nnn

Days”.

ALARM CONDITIONS

Overload

The status messages will be “WARNING” and “Overload” and the audible

alarm will sound. Press the Reset button to silence the alarm and to clear the

status message.

If either the magnitude or the duration of the overload is beyond the capability of

the Converter, it will shut down to the Standby condition. Extreme overload

conditions may cause the Converter to shut down completely, in which case a

Supply Voltage Low indication will also be given.

Investigate and if necessary remove the cause of the overload, observing any

necessary safety precautions before making adjustments to wiring. Restart the

Converter by pressing the green Start Output button on the mimic diagram.

Over Temperature

The status messages will be “WARNING” and “Over Temperature” and the

audible alarm will sound. The Converter will shut down to the Standby

condition.


12

Press the Reset button to silence the alarm and to clear the status message, and

check for any obstruction of the air inlets or outlets around the Converter. If no

such cause can be found, it may be that a cooling fan has failed and will require

replacement.

Restart the Converter by pressing the green Start Output button.

Short Circuit

The status messages will be “WARNING” and “Short Circuit” and the audible

alarm will sound. The Converter will shut down to the Standby condition.

Press the Reset button to silence the alarm and clear the status message.

Remove the cause of the short circuit, taking any necessary safety precautions

before making adjustments to wiring.

Restart the Converter by pressing the green Start Output button.

Inverter Fault

The status messages will be “WARNING” and “Inverter Fault” and the audible

alarm will sound. The Converter will shut down to the Standby condition.

Press the Reset button to silence the alarm and clear the status message, and

restart the Converter by pressing the green Start Output button.

This error condition has a number of possible causes, and may be triggered by

an internal fault. If the failure is repeated it is likely that the Converter will require

repairs. Do not make further attempts to restart the Converter.


13

UNREPORTED PROBLEMS

Some error conditions will cause the Converter to disconnect itself from the

incoming supply, and the resulting absence of internal power will prevent the

display of any message or indication. It will be impossible to start the Converter

until the problem has been solved.

The most likely cause during commissioning or after any changes to the site

electrical installation is a phase rotation fault, and other possibilities are

significant undervoltage or overvoltage of the supply. Any of these causes will

require remedial action either by an electrician or by the supply authority.

It is also possible that an internal fault will prevent starting, in which case a

service visit by an experienced engineer will be required.

ELECTRICAL MEASUREMENTS

The first two lines of the alphanumeric display can provide a number of

indications, including running time since last started, input and output voltage,

and output current as a percentage of the maximum allowed.

The scroll buttons allow these values to be displayed in sequence.

MAINTENANCE

Preventive Maintenance

The intake fans draw air in through vents at the front of the Converter. Exhaust

fans discharge the air through vents at the rear of the unit.

At suitable intervals, check that any visible fans are operating normally, and that

the air intakes are clear of any accumulation of fluff or dust.


14

Corrective Maintenance

Spare parts are available from Magnus Power, and these can be fitted without the

use of special tools. Provided the fault was correctly diagnosed, the Converter

will return to normal operation after replacement of the defective part. In some

cases, best results will be achieved by carrying out specialised adjustment

procedures requiring the use of standard electronic test equipment.

For some failures, the defect and the effect may be in different places; for

example a faulty output from a control printed circuit board may cause failure of

one of the main power components. If only the power component is replaced,

the failure will be repeated.

Because of the high MTBF of these Converters, it will be difficult for an on-site

engineer responsible for only a small number of systems to become familiar with

troubleshooting. The most cost-effective repair option will usually be to have

the fault repaired by an experienced field service engineer. If immediate return to

service after a breakdown is a priority, then a standby unit should be held on

site.

Warranty Repair

The standard Magnus Power warranty covers the cost of any repair that

becomes necessary due to failure while in normal use during the specified

warranty period, usually 12 months. It is unlikely that any unit will be out of

order for more than 2 working days after having been reported as faulty.

____________________________________________________________

___

29 - 30 Brunel Road, St Leonards-on-Sea, East Sussex, TN38 9RT. United KingdomSales - 01424 853013 - All Other Departments - 01424 853464 - Fax - 01424 852268

Registered in England, Registered office Unit 12, Clivemont Road, Cornwallis Ind. Est. Maidenhead SL6 7BZ. Registration No. 4977339. VAT Registration No. GB 829 4203 28

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